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Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 2
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #2
Since 197363 Employees16 mill Euro 2013
ValvesEngineeringAsset ManagementService
Education
Process industry Sweden, Finland, Denmark
Askalon ABAskalon AB
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 3
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #3
1. Products / Valves1. Products / Valves• Fisher Controls
• Globe valves• Rotary valves• Fieldvue positioner• Self acting regulators• Tank blanketing
• Virgo• On-Off Valves
• Enardo• Hatches• Flame arrestor
• TopWorx• Valve Top• GO Switch
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 4
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #4
2. ENGINEERING2. ENGINEERING
Design Engineering CAD drawing Welding Pressure test Assembly PID Instrument PED / CE mark Testing Documentation
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 5
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #5
Gas turbine fuel valve and Flow labGas turbine fuel valve and Flow labPilot valve DN40Main valve DN50
Standard and ATEX
Very quick: 200 mSec full strokeVery accurate: 5/15000= 0,03%
Profibus control
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 6
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #6
EducationEducation Approx. 80-100 students and 20-25 classes
on a yearly basis Courses
– MHM– Fisher Valves– FIELDVUE– AMS/Valvelink
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 8
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #8
Share HolderValue
SafetyIncidents
Availability
MaintenanceCost
…
Results
Reliability is a Business StrategyReliability is a Business StrategyLinks required to createand sustain reliabilityperformance
Annual Report
…
DATA
CONDITION
WORK
RELIABILITY
ReliabilityStrategy
Reliability Value Chain
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 9
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #9
Reactive maintenance costs are 50% higher than planned maintenance costs
Source: 2010 NPRA Reliability and Maintenance Conference
Reliability
Mai
nten
ance
Cos
t Run-to-failure Preventive
Maintenance PredictiveMaintenance Automated
Monitoring
Correlation Between Reliability and Total Maintenance CostCorrelation Between Reliability and Total Maintenance Cost
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 10
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #10CRITICAL MACHINES
Overspeed Protection
MODBUS
AMS:MachineryHealth Manager
…PREDICTION
PlantHistorian PERFORMANCE
PROTECTIONAPI /TSI
BALANCE OF PLANT (Monitoring)ESSENTIAL IMPORTANT SECONDARY
AMS: Asset Performance Management
CMMS
Existing Protection Sys
SMARTWIRELESSGATEWAY
AMS: Performance Advisor
OPCOPC
WorkOrders
MAINT. Actions
AMS:IntelligentDevice Manager
Instrument,Valves &Drives
PROCESSCONTROL
Emerson Plant-Wide Reliability Solutions
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 11
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #11
Machinery Health SolutionsMachinery Health Solutions
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 12
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #12
Criticality of Machinery AssetsCriticality of Machinery Assets
Heat Exchangers
Pumps
Cooling Towers
Blowers / Fans
Air Cooled Heat Exchangers
Turbines
Generators
Generators
Motors
Fans
Gears
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 13
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #13
Online Machinery MonitoringProtection, Prediction, Performance MonitoringOnline Machinery MonitoringProtection, Prediction, Performance Monitoring
Operations Maintenance
Machinery Protection• Avoid catastrophic failures• Increase safety• Satisfy insurers
Performance Monitoring• Maximize production• Reduce energy used• Minimize emissions
Predictive Diagnostics• Maximize availability• Increase dependability• Reduce maintenance costs
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 14
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #14
Criticality of Machinery AssetsCriticality of Machinery Assets
Heat Exchangers
Pumps
Cooling Towers
Blowers / Fans
Air Cooled Heat Exchangers
Turbines
Generators
Generators
Motors
Fans
Gears
[File Name or Event]Emerson Confidential27-Jun-01, Slide 15
Machinery Protection SystemsMachinery Protection Systems Critical rotating assets require protection systems
– Internal company requirements, best practice– Insurance, safety
API-670 was formed to provide recommended guidelines– Sensor configurations and installation recommendations– Minimum requirements for monitoring systems– End users adopt the API-670 recommendations as their best
practice standards
Machinery Protection
[File Name or Event]Emerson Confidential27-Jun-01, Slide 16
Machinery Prediction SystemsMachinery Prediction Systems Uses the data provided by the Machine Protection
System Prediction Systems considerably enhance the utility of a
Machine Protection system by providing actionable information to operators and engineers which can prevent a sudden plant trip or requirement for emergency shutdown of the machine or process
Predictive Diagnostics
[File Name or Event]Emerson Confidential27-Jun-01, Slide 17
Why Prediction? For Start-up, Coast-Down and Production State MonitoringWhy Prediction? For Start-up, Coast-Down and Production State Monitoring
Shaft cracks Coupling degradation Bearing condition and lubrication
changes Alignment Foundation, piping resonance
changes Imbalance changes Bump in the night capture and
replay Predictive planning for next
outage See inside the turbine, make
decisions fast and early
Prediction serves as protection for your bottom
line
Predictive Diagnostics
[File Name or Event]Emerson Confidential27-Jun-01, Slide 18
Performance Monitoring What Do We Mean?Performance Monitoring What Do We Mean? Basically – “How Well Is An Asset Doing Its Job” Thermodynamic Analysis
How much of the ENERGY IN….. Electrical PowerSteamWaste GasHeat Fuel
….. is converted to USEFUL ENERGY OUT! Power FlowHeat Etc.
Compared to what we expect the unit to achieve
Performance Monitoring
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 19
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #19
Turbomachinery InstrumentationTurbomachinery Instrumentation
Green = measurements are monitored by operators to optimize turbine ramp rateBlue = machinery shutdown on high vibrationThrust and Overspeed are most critical shutdown parameters
Bearing Vibration
6110
Bearing Vibration
6110
Bearing Vibration
6110
Bearing Vibration
6110
Dual Thrust Position6210
Temperature 6220 Case Expansion
6410
Eccentricity6220
Speed/Phase 6312
Differential Expansion 6210
Valve Position
6410
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 20
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #20
Machinery Events:Controllable, Predictable or UnpredictableMachinery Events:Controllable, Predictable or Unpredictable
Equi
pmen
t Hea
lth
0%
100%
Time
Predictive Diagnostics and Performance Monitoring provide the advanced warning necessary for business decisions
Effective online machinery monitoring addresses all three situations
Controllable Predictable Unpredictable
Machinery Protection
Predictive Diagnostics
Performance Monitoring
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 21
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #21
21
Am
plitu
d
Frekvenz
Spectrum
Protection vs PredictionProtection vs Prediction
Protection Total Vibration
Prediction System utilize frequency bandUnbalance
Coupling
degradation
Pea
k-P
eak
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 22
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #22
Unpredictable EventsUnpredictable Events
User BenefitsSudden Events Can Occur Without Warning • Prevent catastrophic machine
damage• Protect human safety• Avoid environmental releases• Meet insurance requirements
• Operations induced• Metal fatigue cracks• Component failure• Process upsets
PlantWeb AdvantageThe Solution
• Integration with process automation systems enables orderly shutdown of complete unit while protecting the asset
• Integrates protection capabilities with predictive diagnostics and performance monitoring
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 23
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #23
Predictable EventsPredictable Events
• Imbalance• Misalignment• Rubs• Rotor bow
• Bearings faults• Oil instabilities• Cracked shaft• Coupling issues
• Improve plant uptime• Plan labor and parts• Prioritize maintenance activities • Extend mean time between repair• Aide process control decisions
with real-time asset information
Early Fault Detection
• Most comprehensive predictive diagnostics for turbomachinery and other rotating equipment
• Diagnostics extend to field devices
• Performance monitoring provides insights
User Benefits
PlantWeb AdvantageThe Solution
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 24
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #24
Controllable EventsControllable Events
• 40-50%* of equipment breakdowns due to poor operating practices
• Take action to avoid downtime / machine damage
• Optimize operation to extend equipment life
• Ramp rate• Load / speed changes• Lube oil temperature, pressure,
flow• Steam temperature
* Ron Moore, Making Common Sense Common Practice
Take Action Before Affecting Machine Health
• Integration with process automation systems provide real-time actionable feedback to operators
• Operators receive machinery information alongside process data and field device diagnostics
User Benefits
PlantWeb AdvantageThe Solution
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 25
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #25
CSI 6500 Machinery Health MonitorCSI 6500 Machinery Health Monitor
Transient Analysis
Predictive Diagnostics
ProtectionAPI 670
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 26
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #26
Protection & Prediction diagnostic system, CSI 6500Protection & Prediction diagnostic system, CSI 6500
CSI 6500 Machinary Health Monitor
Junction Box
Server
Plant LAN
Ethernet
Wireless LAN
Multi cable
Sensor cable
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 27
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #27
Dual, Redundant 24 VDC PowerDual, Redundant 24 VDC Power
CSI 6500 Machinery Health Monitorfor Critical MachinesCSI 6500 Machinery Health Monitorfor Critical Machines
API 670 Compliant ProtectionFull turbine supervisory instrumentation
API 670 compliant
Hardware• 19” rack mount• Hot swappable protection cards
Relay Module• 2-out-of-3 Voting• Flexible Voting Logic• Alert, Danger, OK and System relays• Time Delay• Trip Multiply
Buffered Outputs• Raw vibration waveform• Connectivity with any data collector for balancing, recording or machine diagnostics
4-20mA Outputs• Provides analog input to PLC’s or process control proportional to vibration
2-Ch, Micro-processor based Monitors• Independent monitors• Extensive self-checking• Self-temperature monitoring
Rack Interface Communication Module• Modbus• Dual-path Serial • Ethernet
TSI = Turbine Supervisory Instrumentation
Full TSI• Case Expansion• Differential Expansion• Eccentricity• Thrust position• Relative Vibration• Temperature• Speed• Zero speed• Absolute Vibration
Full TSI• Case Expansion• Differential Expansion• Eccentricity• Thrust position• Relative Vibration• Temperature• Speed• Zero speed• Absolute Vibration
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 28
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #28
CSI 6500 Machinery Health MonitorCSI 6500 Machinery Health Monitor
Control system style field-based predictive processor
Control system style field-based predictive processor
PeakVue for rolling element and gearboxes
PeakVue for rolling element and gearboxes
Predictive MonitoringField based intelligence
API 670 Compliant Protection Full turbine supervisory instrumentation
Full integration to the AMS SuiteFull integration to the AMS Suite
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 29
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #29
Trend ofBalance
Trend of Bearings
Alarm
Am
plitu
deSub-
Harmonic 1X 2X Bearing Bearing Gears Bearing
1x 2x 50x
5mm/sec
1mm/secTime
(Days)Time(Days)
Prediction, Narrow Bands with trendPrediction, Narrow Bands with trend
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 30
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #30
Data Collection SetDifferent alert levels at different operating conditions.Data Collection SetDifferent alert levels at different operating conditions.
Unique alarm limits at :– Startup– Run out– If RPM<500 alert set 1 – If RPM>500 Alert set 2– If RPM>1000 Alert set 3– If RPM<1400 Alert set 4…
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 31
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #31
CSI 6500 Machinery Health MonitorCSI 6500 Machinery Health Monitor
Transient Analysis For Turbomachinery
Transient analysis for turbomachineryTransient analysis for turbomachinery
Predictive MonitoringField based intelligence
API 670 Compliant Protection Full turbine supervisory instrumentation
100+ hour transient data recording100+ hour transient data recording
Live View ModeLive View Mode
Replay Mode of recorded data Replay Mode of recorded data
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 32
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #32
Transient / Live ModeTransient / Live Mode
1. Data extraction of all diagnostic data from each CSI 6500 for the past 100 hours with 6400 lines (up to 5X per second sampling rate)
Real-time plotsPolarBodeSpectrumOrbitWaveformCascadeShaft Centerline
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 33
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #33
SensorsSensorsSensors• Accelerometers
• Industrial• Test & Measurement
• Velocity Sensors• Displacement Sensors• 4-20 mA Output Sensors
Cables/Connectors• Twisted, Shielded Pair • Drain Wire• Heavy Gauge, Twisted Stand Wire• Kevlar Strength Member• Heavy Duty Jacket
Mounting Hardware• Magnets• Quick connect• Pads• Mounting tools• Zerk Adapters• Adaper studs & Screws
Junction Boxes• Switch Boxes• Signal Management Boxes• Cable Termination Boxes• Cable Reduction Boxes• MAXX Boxes
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 34
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #34
AMS Suite : Asset Graphics Graphic package to visualize machines and
machine condition
Trend capability to view history and live trends
Open connectivity integrating multiple data sources
– Vibration
– Process parameters
Notification package
– Alarms and events screen
– Notification (email)
- OPC and Modbus compliant -
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 35
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #35
Performance tabPerformance tab
Asset Graphics start ViewAsset Graphics start View
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 36
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #36
Protection tabProtection tab
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 37
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #37
Prediction tabPrediction tab
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 38
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #38
Performance tabPerformance tab
[File Name or Event]Emerson Confidential27-Jun-01, Slide 40
Questions?Questions?
Our global customer knowledge sharing event and technology exhibition.
300+ papers and work shops.
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 41
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #41
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 42
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #42
Asset Performance Management- User Focused Home PageAsset Performance Management- User Focused Home PageUser Focused Home Page
Emerson OverviewEmerson ConfidentialRevised 17-Feb-06, Slide 43
Emerson OverviewEmerson ConfidentialRevised 20-Mar-06, Slide #43
Rank Data for Analysis and Action